Interconnection The power of single-cable solutions
Traditionally, industrial automation has relied on multi-cable systems, whether these connect sensors and actuators or help manage data and power. These systems aren’t without their challenges, and the extensive wiring and large machine footprints involved can be a drawback. However, single-cable systems can simplify things immensely, helping manufacturers achieve greater efficiency, reduce material usage and futureproof their operations, explains Chris Knight, product specialist – I/O at Beckhoff UK.
T
he move towards single-cable technology has been driven by modern communication protocols like Profinet, EtherCAT and Ethernet IP. As these
have replaced older systems, the need for extensive planning for cable runs connecting sensors, actuators, and other devices to a central signal processor has reduced. For example, distributed I/O systems have minimised reliance on multiple cable sensors by using fieldbus cables.
Single-cable solutions also enable simplified connections using a straightforward plug-and-play approach. Standardised connections, like the M8 and M12 connectors, can make design and installation, debugging, and general maintenance easier.
Strength isn’t always in numbers Traditionally, industry has relied on centralised I/O systems, running sensor and actuator cables back from remote devices. These signals were a mixture of analogue and digital signals, conveying all the information from the machine. As well as being vulnerable to interference, these communication systems required multi-cable setups that involved extensive planning, signal protection and large trunking — which only added to costs. Consequently, these older systems resulted in a large machine infrastructure footprint and a high volume of materials, such as metal and wiring, were required. Needless to say, this made it time-consuming and costly for manufacturers to deliver on sustainability commitments and productivity KPIs. To see the benefit of this single-cable approach, look no further than motor technology — an area of incredible development. Manufacturers now have the choice of a new generation of drive motors that support One Cable Technology (OCT), such as the AMP8000 servomotors. These have removed the need for separate power and feedback for drives, even removing the need for drives completely, significantly streamlining machine design and operation.
22 July/August 2025
Single-cable systems are robust, making them a dependable choice for modern industrial automation. A key advantage is the durability and precision of Ethernet-based communication technologies, which are replacing older bus systems, providing faster communications, simpler cabling and larger IO counts. Foundational technologies like Profibus and CAN paved the way for today’s advanced and reliable fieldbus systems. By integrating these advancements with the streamlined simplicity of single-cable designs, modern automation systems achieve greater efficiency, reduced complexity, and enhanced reliability — all in one.
It’s safe to say that single-cable solutions, like those using Beckhoff’s ENP, ECP or EtherCAT P, are no longer the niche — they have become industry standards embraced by manufacturers across various
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industries. Widespread adoption by global industry leaders means businesses can invest confidently in proven technologies. This growing ecosystem of single-cable technologies enables businesses to future- proof their automation setups with access to ongoing advancements and long-term support.
Getting started
Introducing single-cable solutions requires careful consideration. For manufacturers just coming into the industry or starting from scratch, these systems offer an opportunity to design streamlined installations. This allows reduced, cabinet and machine fit out times, reduced wiring costs and minimal maintenance requirements. Meanwhile, these advantages can be attractive selling points for customers, as simpler systems usually result in fewer operational issues.
For more established companies, it is
important to balance the cost of upgrading existing systems against the long-term benefits of reduced complexity, material use and maintenance demands. Single-cable technology can be applied across many industries, from packaging to specialised environments like ATEX-zoned areas. Whatever the application, manufacturers must prioritise compatibility, ensuring any new solutions are suitable and will deliver a good return on investment.
Single-cable solutions like ENP, ECP and EtherCAT P transform industrial automation by simplifying installations, reducing machine footprints, and enhancing system reliability. As more manufacturers adopt this technology across a range of applications, it will quickly become a future-proof choice for those wanting to optimise efficiency and enhance sustainability.
https://www.beckhoff.com/en-gb/
www.cieonline.co.uk
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